CTI SYMPOSIUM 2018: 17th International Congress and Expo 3 - 6 December 2018, Berlin, Germany

367 Pages·2020·23.561 MB·German-English

Proceedings
CTI SYMPOSIUM
2018
17th International Congress and Expo
3–6 December 2018, Berlin, Germany
Proceedings
Ein stetig steigender Fundus an Informationen ist heute notwendig, um die immer
komplexer werdende Technik heutiger Kraftfahrzeuge zu verstehen. Funktionen,
Arbeitsweise, Komponenten und Systeme entwickeln sich rasant. In immer sch-
nelleren Zyklen verbreitet sich aktuelles Wissen gerade aus Konferenzen, Tagungen
und Symposien in die Fachwelt. Den raschen Zugriff auf diese Informationen bietet
diese Reihe Proceedings, die sich zur Aufgabe gestellt hat, das zum Verständnis
topaktueller Technik rund um das Automobil erforderliche spezielle Wissen in der
Systematik aus Konferenzen und Tagungen zusammen zu stellen und als Buch in
Springer.com wie auch elektronisch in Springer Link und Springer Professional
bereit zu stellen. Die Reihe wendet sich an Fahrzeug- und Motoreningenieure sowie
Studierende, die aktuelles Fachwissen im Zusammenhang mit Fragestellungen
ihres Arbeitsfeldes suchen. Professoren und Dozenten an Universitäten und
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Gutachtern, Forschern und Entwicklungsingenieuren in der Automobil- und
Zulieferindustrie sowie Dienstleistern können die Proceedings wertvolle Antworten
auf topaktuelle Fragen geben.
Today, a steadily growing store of information is called for in order to understand
the increasingly complex technologies used in modern automobiles. Functions,
modes of operation, components and systems are rapidly evolving, while at the
same time the latest expertise is disseminated directly from conferences, con-
gresses and symposia to the professional world in ever-faster cycles. This series of
proceedings offers rapid access to this information, gathering the specific knowl-
edge needed to keep up with cutting-edge advances in automotive technologies,
employing the same systematic approach used at conferences and congresses and
presenting it in print (available at Springer.com) and electronic (at Springer Link
and Springer Professional) formats. The series addresses the needs of automotive
engineers, motor design engineers and students looking for the latest expertise in
connection with key questions in their field, while professors and instructors work-
ing in the areas of automotive and motor design engineering will also find sum-
maries of industry events they weren’t able to attend. The proceedings also offer
valuable answers to the topical questions that concern assessors, researchers and
developmental engineers in the automotive and supplier industry, as well as service
providers.
More information about this series at http://www.springer.com/series/13360
Euroforum Deutschland GmbH
Editor
CTI SYMPOSIUM 2018
17th International Congress and Expo 3–6
December 2018, Berlin, Germany
Editor
Euroforum Deutschland GmbH
Düsseldorf, Germany
ISSN 2198-7432 ISSN 2198-7440 (electronic)
Proceedings
ISBN 978-3-662-58865-9 ISBN 978-3-662-58866-6 (eBook)
https://doi.org/10.1007/978-3-662-58866-6
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Diversity in Intelligent, Electrified Automotive
Drives
The rapid progress of digital transformation and faster evolution in automotive
development will have a long-term effect on automotive drives. In a few years’
time, machines will hold meaningful conversations with humans and will ‘know’
their habits and moods. This will enable user-oriented driving functionality, and
hence optimized vehicle operating strategies. Already, large companies are moving
fast to extend their digital competence by buying up smaller digital specialists.
The diversity of concepts, energy sources and charging modi in automotive
drives is stronger than ever, which in turn increases their complexity. The next
five years will see an ‘electromobility rollout’ with a broad portfolio of electric
vehicles that enable ranges of 500 km or higher, plus significant extensions to
infrastructure. By 2025 at the latest, more and more BEVs will meet customer
expectations – and not just because of the medium-range price parity with conven-
tional automobiles that experts predict in specific segments.
Nevertheless, combustion engines – whether diesel or petrol – will still be the central
pillar of automotive drives for a long while. Together with legal framework parameters,
‘reality checks’ from the energy and automotive industries continue to pour cold water
on the euphoria generated by some electromobility players. However, signicfi antly
more electriefi d drive concepts – from 48 V mild hybrid through to plug-in hybrid
drives – will enter mass production. Long term, some large carmakers now predict over
70% market share for hybrid drives by 2050. In addition to numerous add-on hybrid
concepts based on familiar MT, AMT, DCT and CVT transmission concepts, the future
will also see more DHT concepts such as multi-mode, powersplit or serial hybrid.
Once again, this CTI SYMPOSIUM in 2019 addressed issues relating to all aspects
of the automotive, transmission and drive industry. In addition to new concepts for
transmissions, hybrid and electric drives, this includes production technology and
component-related topics for passenger automobiles and commercial vehicles, and the
inufl ence of connectivity and automated driving on tomorrow’s drives:
• Market and regulatory developments and their impact on drives
• New hybrid, electric and fuel cell drives for passenger cars, trucks and buses, in
part connected and automated
v
vi Diversity in Intelligent, Electrified Automotive Drives
• 48 V Mild Hybrid for various drives and markets
• New AT, DCT, CVT and MT concepts with innovations to boost comfort and
efficiency, and their modular hybridization
• Various DHTs (Dedicated Hybrid Transmissions) for new hybrid drives
• Drives with up to 3 ratios for EV drives, e-axles, high-rpm concepts
• Conventional and electrified all-wheel drives, torque vectoring
• Semiconductors, electric motors and batteries as key technologies in electrified
drivetrains
• Next-generation oils and lubricants for electrified drivetrains
• Virtual, customer-oriented development using AI to determine efficiency, drive-
ability and longevity
• Test beds for EV and FCEV drives to examine and safeguard safety-relevant
states
• Compact, efficient driveaway and shift elements, eClutch, claw clutch, absorber
solutions, torque and pressure sensors
• Production: lightweight battery construction, electric motors, transmissions,
new solutions with additive production, powder metallurgy
The wide range of topics was addressed in a comprehensive programme that
included 10 expert plenary talks and 16 parallel lecture series. In the panel dis-
cussion, vehicle, mobility and drive experts were addressed a topic cluster titled
‘Which energy source will power tomorrow’s mobility? What are its implica-
tions for the drivetrain?’. All this was flanked by CTI SYMPOSIUM EXPO – the
‘Hands-On Technology Market for Innovative Products’ with 125 exhibitors.
Together with the introductory day for industry newcomers and the annual
CTI TEST DRIVE with various drive and transmission concepts, the 17th CTI
SYMPOSIUM in Berlin offered outstanding opportunities for international trans-
mission and drive specialists to exchange ideas and opinions. It also provided inval-
uable updates on where we stand – and fascinating insights into what lies ahead.
More: www.drivetrain-symposium.world
Save the date:
Contents
A 25 kW 48 V Mild Hybrid Motor and Inverter ..................... 1
Lawrence Alger, James Haybittle, Anthony D. Wearing,
Cedric Rouaud, and William D. Drury
Compact and Efficient Electric Propulsion Systems Enabled
by Integrated Electric Controllable Clutches ........................ 20
Carl Beiser
Transmission Durability Objective Assessment: A Method
to Estimate Durability Requirement ............................... 43
G. Camboni, M. Ferraccioli, and P. Gili
HRAM: Hybrid Rear Axle Module, an Innovative Hybrid
Differential for P3 and P4 Applications ............................ 73
Carlo Cavallino, Sergio De Santis, and Peter Riemer
P2 Hybridization - Tailored Solutions .............................. 80
Martin Dilzer
The Drivetrain for the New Mercedes-Benz Compact Cars ............ 87
Christoph Dörr, Servane Lessi, Marcus Adolph, Volker Marx,
and Florian Veik
Anthropometric Analysis in Automotive Manual Transmission
Gearshift Quality Perception ..................................... 97
Edson Luciano Duque and Plinio Thomaz Aquino Jr.
48 V Hybridization ............................................. 110
Thomas Eckenfels, Andreas Kaksa, and Christian Marek
Development of a Technical Solution Aimed to Improve Customer
Acceptance of Reverse Gear Engagement Quality ................... 120
Pietro Esposito, Gianluca Camboni, and Salvatore Manolio
vii
viii Contents
Evaluation of Wear in an Automotive Transmission Using Powder
Metal (PM) Gears .............................................. 135
Anders Flodin
From Vehicle Manufacturer to Mobility Service Provider – Business
Challenges of Electromobility for OEM and Supplier ................ 143
Wilfried Funk and Benedikt Strigel
Lubricant Concepts for Hybrid Electric Vehicle (HEV)
Transmission .................................................. 153
Michael Gahagan
The Next Generation DCT-Transmission for Mercedes-Benz
Compact Vehicle Family ......................................... 163
Alexander Harsch, Benjamin Kemmner, Andreas Ertel, and Anton Rink
Hybridization Requires New Clutch Systems ....................... 176
Joachim Hoffmann and Karl-Ludwig Kimmig
Modular E-Drive Concepts for Light to Heavy Electric
Trucks and Buses .............................................. 187
Martin Huber, Heimo Schreier, Jürgen Tochtermann, and Martin Ackerl
100 Experts, 1 Opinion: Predicting Future Electric Vehicle
and Powertrain Component Sales ................................. 196
Malte Jaensch and Hannes Bantle
Game-Changing Lightweight E-Motor Design Enables Unrivalled
In-Wheel Drives and Other Applications ........................... 210
Roland Kasper
New All-Wheel Drive Systems in the Conventional and Electrified
SUV Drivetrain of Mercedes-Benz ................................ 226
Ralf Koesling, Sven Stöhr, and Volker Marx
Development of a Virtual Reality Simulator Test Bench
Capable of Validating Transmission Performance of
Drivability using a Virtual Engine ................................. 243
Hiroki Kumashiro
The Pedelec as a Plug-In Hybrid - Innovation Through an
Automotive Technology Transfer .................................. 253
Bernhardt Lüddecke, Joerg Brandscheid, Stephan Rebhan,
and Hermann Meyer
Design of a Hyper-High-Speed Powertrain for EV to Achieve
Maximum Ranges .............................................. 265
Marco Mileti, Patrick Strobl, Hermann Pflaum, and Karsten Stahl
Contents ix
Development of a New Hybrid Transaxle for 2.0L Class Vehicles ....... 274
Nobuhito Mori, Yuki Hiura, Mitsutaka Matsumura, and Kazuya Shiozaki
Ultra-High Accuracy Technology for Measuring Transient
Transmission Efficiency ......................................... 282
Shintaro Ohshio
Lightweight Forging: Potentials in the (Hybrid) Powertrain
with Forged Components ........................................ 292
Hans-Willi Raedt, Thomas Wurm, and Alexander Busse
Leveraging Connectivity and Automation to Improve Propulsion
System Energy Sufficiency ....................................... 300
Darrell Robinette, Bo Chen, Pradeep Bhat Joe Oncken, Josh Orlando,
and Neeraj Rama
GKN’s ActiveConnect AWD System as an Energy-Efficient
Solution for Electrified Vehicles ................................... 310
Christoph Schmahl, Michael Höck, Dirk Ressin, and Mathias Kesseler
Critical Safety Issues for EV, FCV and Useful Testing Machines
to Solve Them ................................................. 319
Takashi Shibayama
Benefits of Hybrid P2 Off-Line Module Compared to
Other Architectures ............................................ 334
Norberto Termenon, Gilles Lebas, and Thibault Meert
Topology Comparison of 48 V Hybrid Drivetrains with
Manual Transmission ........................................... 347
Matthias Werra, A. Ringleb, J. Müller, and F. Küçükay
Author Index .................................................. 357